STAMPING PROCESS
A. Definition Stamping Process
The stamping process is as cold metal molding process using dies and press machines generally plate printed, to produce in accordance with the desired product diemold's blog. accessed from.
B. - things that need to be considered in Stamping Process
1. If Dies too large, the engine used less tonnage, inadequate, not thinking of the safety factor, will cause the machine easily damaged, especially on the bearings and crankshaft, as well as the motor may burn due to over load.
2. If the stroke setting is too high, the resulting product is not good reject.
3. If the stroke is too low will cause the upper die and lower die collision, the dies can be broken.
4. If the upper die and lower die due slider stroke centers not worn (already hilarious), then the resulting product is not good reject.
5. If the guide post and guide bush is worn or not center, products are not good.
6. If the blanking clearance between the upper die and lower die, too little can lead to die during stamping can not be opened, or it could also die quickly wear out, If the clearance is too large will rapidly cause bari.
7. If the hardening die die fragile too hard, too soft when hardening die die easy to wear.
8. If the election material was not good die, die quickly broken.
9. If the material thickness tolerance pressed too high will cause rapid deterioration die. The product is not good.
10. If the material hardness unstable pressed, will cause the die easily damaged, and the product is not good.
11. If the bearing is worn bearing in the machine, especially on the parts related to stroke, Die can be easily damaged, or the product is not good.
12. If the design of die lack expertise, in terms of the design of die, then maybe the die will be broken, the product is not good.
13. If the components die of components with low quality of, will cause rapid deterioration die, the product is not good.
C. Kinds - kinds of Stamping Process
In general, the processes contained in the stamping process is grouped into three parts:
1. Cutting Process (cutting).
The cutting process is a process where material is cut according to the desired size so that the material can be worked into the next process. Type - the type of cutting processes, among others:
a. Blanking
Blanking is the process of preparing the material, the material is cut as required. Blanking process aims to get the piece or blank, while the rest will be disposed of as garbage or so-called scrap.
b. Cutting
That is a process that is still shaped cutting sheet material (blank material). The cutting process is the process of cutting some part of a part. The rest of the cuts discarded as scrap.
c. Trimming
That is a process of cutting the material at the edges. Usually this process is a continuation of previous processes such as draw, stamp and so on.
b. Notching.
Notching is on the edge of the cutting process the material part, usually on progressive dies. With these cuts, part gradually formed while still attached to the scrap skeleton.
c. Parting or Separating
Parting or separating is the process of separating a part into two parts or multiple parts from sheet metal strip so as to produce the desired part. In the process of separating scrap are unused.
2. Forming Processes (formation).
Forming is a general term that is used in sheet metal forming process to obtain the desired contour. Forming process, not result in a reduction or removal of material as happens in the cutting process. So to term formation also vary so that no misunderstanding. The types of forming processes include:
a. Bending
Bending is a process of bending the plate where the results of this bending a line in accordance with the form of the desired angle.
b. Flanging.
Flanging is the same as bending but the resulting bending lines are not straight but follow the shape of the part in question. This process is intended to strengthen the sides of the product or to reason, beauty.
c. Forming.
Forming refers to a more narrow sense which means it is the deformation of sheet metal that is a combination of bending and flanging process. Forming process produces highly complex shapes by bending-bending and complicated contour parts.
d. Drawing.
Drawing is forming deep enough so that the formation process requires a blank holder or stripper and water cushion / spring to control the flow of material. For irregular shapes bead necessary to balance material flow. To produce a good product, you should use a special steel sheet drawing process and use hydraulic press machine.
e. Deep Drawing.
Deep Drawing a deep drawing process so as to get the shape and size of the final product required several times a drawing process. Blank holder / stripper absolutely necessary and can only be processed on hydraulic press machine and uses a special metal sheet for deep drawing.
3. Process Compression (emphasis added).
This process includes the forming operation in which a strong emphasis is given to the sheet metal to produce a high compression stress on the plate to produce plastic deformation. Types of emphasis process are:
a. Stamping or Marking.
Marking or stamping or sometimes called coining process is used to make signs, symbols, letters or other forms of cold forging process.
b. Heading.
Heading is the process of formation of the head part, usually on steel material bar. Forming process with the process of hot forging or cold forging where the ends of the parts are processed using the pressing dies to form the head.
c. Sizing.
Sizing is an operation in which the plate material given the high pressure which causes the material to flow, therefore sizing aims to increase the dimensional accuracy of the part / workpiece.
D. Tool - Supporting tools Stamping Machine.
In addition to the press machine Stamping Process in conducting production also requires a tool - a tool to support the pressing To produce good quality.
Support tools press machines, among others:
1. Dies
Dies is a mold that is driven by a pressing machine for pressing or pressing / material to produce goods in accordance with the example. Dies materials used are: general, special stainless alloy, which can be done hardening process to HRC hardness above 60, for example: DC 53, SKD 11, etc. There are some parts that are important dies: For example cavity, Guide Post, Upper plate Lower Plate.
In general, dies construction is divided into two parts, namely:
a. Single Operation Dies.
Single Operation Dies or so-called single dies is the construction of dies that have a process on its die set and only produce a part in one stroke. Part produced can be a result of blank, part of semi-finished or finished goods part.
Kind of - kind of a single operation dies, among others:
1) Cut Off Die.
Cut off used only for the die cutting process with the aim of cutting blanks, separating or cutting scrap. Cut off the die is also often combined with a blanking process for cutting scrap. Cutting blank with die cut-off is limited to a simple blank and accuracy are required.
2) Cut Off and Drop Through Blanking Die.
Cut Off and Drop Through Blanking Die blanks used for the process of cutting, only the results of the cuts will fall to the bottom of the die passes through a hole in the engine bolsters and into shelters. Cut off very efficient in the use of materials as scrap is wasted very little.
3) Drop Through Die.
Drop Through Die or with other terms Through Die Blank is the construction of press dies whose products fall to the bottom of the die and passing through the hole on the machine bolsters and into shelters. Construction dies like this in general for blanking process and to dispose of scrap in the process pierching. For this type of construction requires stripper dies to hold the material when the dies are at work. Inverted Die or other terms of Return-Type Blanking Die is die blank where the results would fall to the bottom die, but returned to the top in the same position during cutting. This mechanism may occur due to the lifting pad back blank results because of the force that presses spring or urethane pad upwards. Sometimes the arrangement of the punch and die reversed by putting the punch down and die on top, with a blank thus produced will be above that then the knockout mechanism.
b. Multi Operation Dies.
Multi Operation dies Dies are designed to work on two or more operations in one stroke. Construction dies because it is more difficult to look for height 4 die suitability of these processes. If the height of his die is not the same then the resulting part is not in accordance with the desired specifications of the product drawing. Various multi operation dies are:
1) Compound Dies.
Compound Dies is a combination of two or more processes related to one means two or more processes are designed on the one dies. The time the process is carried out simultaneously. Option to create a compound dies depends on several considerations, among others:
a) Cost of production
b) Cycle time is short
c) Accuracy part
d) saving machine usage
2) Combination Dies.
Combination Dies or a term commonly called Group Tool, Process Gang or Family Dies which means it is a combination of two or more processes on a single die sets which are not parallel use. This means that on a single die set there are two or more processes. In one stroke resulting number of parts corresponding to the number of existing processes on a single die set.
3) Progressive Dies.
Progressive process: The process of printing / stamping is done all in one process dies. The whole process is done in one dies, so that once printed the final product has been directly obtained. Progressive Dies consists of multiple processes or multiple station interconnected originating from the same material. In the progressive dies generally use coil (steel sheet coils) and a coil feeder as a driver coil automatically. Part processed from the beginning will continue on a sheet attached to the plate until the last process. Prices progressive dies are very expensive, therefore only products that are high-volume production using press dies of this kind.
2. Press Machine.
Press machine is a machine that carry the a foundation and a pestle, a power source, and a mechanism that causes pounder moving straight and upright toward the foundation. Press machine itself many kinds, the most important to the press machine is a precision stroke and tonnage capacity, the capacity of the smallest tonnage of under 1 ton up to the largest hundreds if there are thousands of tons. A small capacity of course for a small product, the greater the greater the products that can be made.
Kind of - kind of press machine, among others:
a. Machine O.B.I. Prees
One press machine that is often found in the market is OBI Press (Open-Back Inclunable, Punch Press).
When we see O.B.I. pangerjaan press suitable for stamping, blanking, forming, drawing, perforating (hollow), embossed, coining, coining, notching, bending, shearing (cutting).
Variable speed motor depending on the engine. To change the speed required in accordance penggentian pully speed of movement required.
b. GAP machine Press.
GAP Press has a full body that handles workmanship plate keras.Alat length and width, and also provide space around the dies. GAP Press commonly used for regular stamping.
c. Horning Press.
Horning press cylinder used on objects. Used for seaming (seam), puncing, embosing. This machine is equipped heading wide in the bed .Beban imposed in dies vertically. The voltage received by the side frame. But in fact occurred small tendency to punch and die. In the press machine of this type was different ways to run the operation of RAM. Single crank generally only able to be used on light suppression. Heavy construction added to the crankshaft to distribute the load evenly on the slide.
d. Hydraulic machines Prees.
Hydraulic press used specifically for the working drawing because its operation is slow so it is not suitable for production activities. Hydraulic press was made for the operation of such deed - draw forming, straightening, plastic molding, dic spotting, and powered compacting metal. This machine can not be used on heavy construction blanking and punching ..
e. Machine Turret Press.
Press turret machine consists of upper and lower turret carrier, which brings punches and dies with varying sizes. Beater (punches) directly above and below it there dies. This machine can make a hole that size varies. Turret punch press with varying tape controller is available in 15-150 ton capacity. Numerical - positioing control can make 65 holes per minute with an accuracy of ± 0.004 ".
d. High machine - Production Press Transfer and Others.
Press transfer machine for the production work such as ice cube trays (a tray of ice cubes), the oil, and the house lights of vehicles with the average - average 500-1500 pieces per minute. The way it works is: the material is inserted in the machine of rools, then moved from one position to the next by working mechanism.
e. Machine Press Brake.
brake press machine which is set to form the curve and shape the metal, which can handle sheet width and can accommodate multiple dies (grounding). This particular type of engine to elongate, bent straight. Brake press machine is ideally used for Corrugating work, seaming, notching, embossing, wiring, or curling and forming cylindrical tube tapers.
f. Machine Shears (Scissors).
Machine shears (scissors) are classified as follows:
1) The cutter blades (blade shear).
2) billets, or scissors structure.
3) Nibbler.
This machine is designed for cutting metal with a knife to cut the sheet - the sheet plate. Knives be operated by foot pedals, fingers hold the plate to be cut. Before cutting plate specify the cutting line, when it is appropriate, press the pedal.
3. Material plate
The materials used for this stamping process generally is a material that has a low hardness, can also be said material class low carbon steel, low carbon steel material group is easily bent, pressed, and molded. Examples widely used are: SS41P.
Bibliography :
Rony Sudarmawan Theryo, "Press Dies Maintenance", Astra Manufacturing Polytechnic.
Hilman, Azmi. Design and Analysis of Stamping Dies Bumper Bracket for Product Development Process With Multi Forging Press. FTIUG, Depok, 2005.